U.S. patent number 9,546,148 [Application Number 14/359,203] was granted by the patent office on 2017-01-17 for process for the production of trioxane from aqueous formaldehyde sources.
This patent grant is currently assigned to Ticona GmbH. The grantee listed for this patent is Ticona GMBH. Invention is credited to Michael Haubs, Klaus Kurz, Jurgen Lingnau.
United States Patent |
9,546,148 |
Haubs , et al. |
January 17, 2017 |
**Please see images for:
( Certificate of Correction ) ** |
Process for the production of trioxane from aqueous formaldehyde
sources
Abstract
The present invention relates to a process for producing cyclic
acetal comprising i) preparing a liquid reaction mixture comprising
a) a formaldehyde source, b) an aprotic compound and c) a catalyst;
wherein the total amount of protic compounds is less than 40 wt.-%,
based on the total weight of the reaction mixture; and ii)
converting the formaldehyde source into cyclic acetals.
Inventors: |
Haubs; Michael (Bad Kreuznach,
DE), Lingnau; Jurgen (Mainz Laubenheim,
DE), Kurz; Klaus (Kelsterbach, DE) |
Applicant: |
Name |
City |
State |
Country |
Type |
Ticona GMBH |
Sulzbach (Taunus) |
N/A |
DE |
|
|
Assignee: |
Ticona GmbH (Sulzbach (Taunus),
DE)
|
Family
ID: |
47216340 |
Appl.
No.: |
14/359,203 |
Filed: |
November 23, 2012 |
PCT
Filed: |
November 23, 2012 |
PCT No.: |
PCT/EP2012/073545 |
371(c)(1),(2),(4) Date: |
May 19, 2014 |
PCT
Pub. No.: |
WO2013/076292 |
PCT
Pub. Date: |
May 30, 2013 |
Prior Publication Data
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|
|
Document
Identifier |
Publication Date |
|
US 20140343300 A1 |
Nov 20, 2014 |
|
Foreign Application Priority Data
|
|
|
|
|
Nov 24, 2011 [EP] |
|
|
11190567 |
Nov 24, 2011 [EP] |
|
|
11190574 |
Nov 24, 2011 [EP] |
|
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11190586 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C07D
323/04 (20130101); C08G 65/16 (20130101); C08J
11/28 (20130101); C08G 65/06 (20130101); C07C
47/04 (20130101); C08G 2/36 (20130101); C08G
65/30 (20130101); C07D 323/06 (20130101); C08G
2/10 (20130101); C08J 11/16 (20130101); Y02P
20/10 (20151101); C08J 2359/02 (20130101); C08G
2650/62 (20130101); Y02P 20/125 (20151101) |
Current International
Class: |
C07D
323/04 (20060101); C07C 47/04 (20060101); C08G
65/30 (20060101); C08G 65/16 (20060101); C08G
65/06 (20060101); C08G 2/36 (20060101); C07D
323/06 (20060101); C08G 2/10 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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252913 |
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Mar 1967 |
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AT |
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101665409 |
|
Mar 2010 |
|
CN |
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4137846 |
|
May 1993 |
|
DE |
|
19822598 |
|
Nov 1999 |
|
DE |
|
1012372 |
|
Dec 1965 |
|
GB |
|
1130513 |
|
Oct 1968 |
|
GB |
|
1524440 |
|
Sep 1978 |
|
GB |
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Other References
Yamaguchi, T., et al. "Synthesis of cyclooligomers of formaldehyde
in liquid sulfur dioxide." Chemistry & Industry. (Oct. 23,
1971), vol. 43, pp. 1226-1227. cited by examiner .
New Jersey Department of Health and Senior Services, Hazardous
Substance Fact Sheet. "Boron Trifluoride Diethyl Ehterate." (c)
Apr. 2000. Available from:
<http://nj.gov/health/eoh/rtkweb/documents/fs/0248.pdf>.
cited by examiner .
International Search Report and Written Opinion for application
PCT/EP2012/073545 dated Apr. 15, 2013. cited by applicant .
Yamaguchi T. et al: "Synthesis of cyclooligomers of formaldehyde in
liquid sulfur dioxide", Chemistry and Industry, vol. 43, Oct. 23,
1971 (Oct. 23, 1971) pp. 1226-1227, XP008149518, Society of
Chemical Industry, London; GB ISSN: 0009-3068. cited by applicant
.
Shoujin Su, Philippe Zaza and Albert Renken: Catalytic
Dehydrogenation of Methanol to Water-Free Formaldehyde, Chem. Eng.
Technol. 17 (1994) pp. 34-40. cited by applicant .
Co pending U.S. Appl. No. 14/359,223, filed May 19, 2014. cited by
applicant .
Co pending U.S. Appl. No. 14/359,119, filed May 20, 2014. cited by
applicant .
Co pending U.S. Appl. No. 14/359,308, filed May 20, 2014. cited by
applicant .
Co pending U.S. Appl. No. 14/359,314, filed May 20, 2014. cited by
applicant .
Co pending U.S. Appl. No. 14/359,333, filed May 20, 2014. cited by
applicant .
Co pending U.S. Appl. No. 14/359,594, filed May 21, 2014. cited by
applicant .
Abstract of Japanese Patent--JPH06228126, Aug. 16, 1994, 1 page.
cited by applicant .
Abstract of Japanese Patent JP2007230979, Sep. 13, 2007, 2 pages.
cited by applicant.
|
Primary Examiner: Jarrell; Noble
Assistant Examiner: Kenyon; John S
Attorney, Agent or Firm: Dority & Manning, P.A.
Claims
The invention claimed is:
1. A process for producing a cyclic acetal comprising: reacting a
formaldehyde source in the presence of a cationic catalyst to
produce a cyclic acetal, the formaldehyde source comprising a
material selected from the group consisting of formaldehyde,
paraformaldehyde, and a polyoxymethylene polymer, the cyclic acetal
comprising a material selected from the group consisting of
trioxane, tetroxane, and mixtures thereof, and wherein the reaction
is carried out in a liquid medium comprising a liquid aprotic
compound having a boiling point of 120.degree. C. or higher
determined at 1 bar, wherein the aprotic compound is selected from
the group consisting of organic sulfoxides, organic sulfones,
organic sulfonate esters, and mixtures thereof, and wherein the
amount of the liquid aprotic compound comprises at least 20 wt % of
the liquid medium and wherein the aprotic compound does not
chemically react with the formaldehyde source.
2. The process according to claim 1, wherein the formaldehyde
source is an aqueous formaldehyde solution.
3. The process according to claim 1, wherein the aprotic compound
has a boiling point of 140.degree. C. or higher, determined at 1
bar and wherein the aprotic compound has a relative static
permittivity of more than 15.
4. The process according to claim 1 wherein the liquid medium
comprises at least 40 wt.-%, of the aprotic compound.
5. The process according to claim 1 wherein the aprotic compound is
selected from the group consisting of cyclic or alicyclic organic
sulfoxides, alicyclic or cyclic sulfones, and mixtures thereof.
6. The process according to claim 1 wherein the aprotic compound is
represented by formula (I): ##STR00010## wherein n is an integer
ranging from 1 to 6, and wherein the ring carbon atoms may
optionally be substituted by one or more substituents, selected
from C1-C8-alkyl which may be branched or unbranched.
7. The process according to claim 1 wherein the aprotic compound is
sulfolane.
8. The process according to claim 1 wherein the aprotic compound is
represented by formula (II): ##STR00011## wherein R1 and R2 are
independently selected from C1-C8-alkyl which may be branched or
unbranched.
9. The process according to claim 1 wherein the aprotic compound is
represented by formula (III): ##STR00012## wherein n is an integer
ranging from 1 to 6, and wherein the ring carbon atoms may
optionally be substituted by one or more substituents, selected
from C1-C8-alkyl which may be branched or unbranched; or the
aprotic compound is represented by formula (IV): ##STR00013##
wherein R3 and R4 are independently selected from C1-C8-alkyl which
may be branched or unbranched.
10. The process according to claim 1, wherein the catalyst
comprises trifluoromethanesulfonic acid, perchloric acid,
methanesulfonic acid, toluenesulfonic acid, or mixtures
thereof.
11. The process according to claim 1, wherein during the process a
reaction mixture includes the formaldehyde source, the aprotic
compound, and the catalyst, and wherein the reaction mixture
contains protic compounds in an amount less than about 20
wt.-%.
12. The process according to claim 1, further comprising the step
of separating the cyclic acetal from the liquid medium by
distillation.
13. The process according to claim 1, further comprising the step
of manufacturing polyoxymethylene from the cyclic acetal.
14. The process according to claim 1, wherein the formaldehyde
source comprises gaseous formaldehyde.
15. The process according to claim 1, wherein the catalyst
comprises sulfuric acid.
16. A liquid reaction mixture comprising a) a formaldehyde source,
the formaldehyde source comprising a material selected from the
group consisting of formaldehyde, paraformaldehyde, and a
polyoxymethylene polymer; b) an aprotic compound comprising a
sulfur containing organic compound and c) a cationic catalyst;
wherein the total amount of protic compounds is less than 40 wt.-%,
based on the total weight of the reaction mixture.
17. A process for producing a cyclic acetal comprising: reacting a
formaldehyde source in the presence of a cationic catalyst to
produce a cyclic acetal, the formaldehyde source comprising a
material selected from the group consisting of formaldehyde,
paraformaldehyde, and a polyoxymetnyene polymer, and wherein the
cyclic acetal comprises a material selected from the group
consisting of trioxane, tetroxane, and mixtures thereof, and
wherein the reaction is carried out in a liquid medium comprising a
liquid aprotic compound having a boiling point of 120.degree. C. or
higher determined at 1 bar, wherein to aprotic compound is selected
from the group consisting of organic sulfoxides, organic sulfones,
organic sulfonate esters, and mixtures thereof, and wherein the
amount of the liquid aprotic compound comprises at least 20 wt % of
the liquid medium; and separating the cyclic acetal from the liquid
medium by distillation.
18. A process for producing a cyclic acetal comprising: reacting a
formaldehyde source in the presence of a cationic catalyst to
produce a cyclic acetal, the formaldehyde source comprising a
material selected from the group consisting of formaldehyde,
paraformaldehyde, and a polyoxymethylene polymer, and wherein the
cyclic acetal comprises a material selected from the group
consisting of trioxane, tetroxane, and mixtures thereof, and
wherein the reaction is carried out in a liquid medium comprising a
liquid aprotic compound having a boiling point of 120.degree. C. or
higher determined at 1 bar, wherein the aprotic compound is
selected from the group consisting of organic sulfoxides, organic
sulfones, organic sulfonate esters, and mixtures thereof, and
wherein the amount of the liquid aprotic compound comprises at
least 20 wt % of the liquid medium, and wherein the catalyst
comprises trifluoromethanesulfonic acid, perchloric acid,
methanesulfonic acid, toluenesulfonic acid, sulfuric acid, an acid
ion-exchange material or mixtures thereof.
19. The process according to claim 1, wherein the catalyst
comprises a solid acid ion-exchange material.
20. The process according to claim 1, wherein during the process a
reaction mixture includes the formaldehyde source, the aprotic
compound, the catalyst, and further comprising protic compounds,
the formaldehyde source being present in the reaction mixture in an
amount from about 20% to about 70% by weight, the aprotic compound
being present in the reaction mixture in an amount from about 25%
to about 75% by weight, and the protic compounds being present in
the reaction mixture in an amount from about 5% to about 15% by
weight.
Description
RELATED APPLICATIONS
This present application claims priority to PCT International
Patent Application No. PCT/EP2012/073545 having a filing date of
Nov. 23, 2012, and which claims filing benefit to European Patent
Application No. 11190574.1 filed on Nov. 24, 2011, European Patent
Application No. 11190567.5 filed on Nov. 24, 2011, and European
Patent Application No. 11190586.5 filed on Nov. 24, 2011, which are
all hereby incorporated by reference in their entirety.
The present invention relates to a process for producing cyclic
acetal comprising preparing a liquid reaction mixture comprising a
formaldehyde source, an aprotic compound and a catalyst and
converting the formaldehyde source in the reaction mixture to
cyclic acetals. Further, the invention relates to a liquid reaction
mixture.
1,3,5-Trioxane (hereinafter "trioxane") is the cyclic trimer of
formaldehyde. Trioxane is mainly used as a starting material for
the manufacturing of polyoxymethylenes (POM) which is a high
performance polymer having desirable and exceptional properties in
terms of mechanical, chemical and temperature stability.
Polyoxymethylene polymers are available as homo- and
copolymers.
As the polyoxymethylene market is growing there is a desire on the
side of the trioxane producers to expand their production
capacities in order to satisfy the trioxane demand on a competitive
basis. The major technical process for the production of trioxane
is the conversion of aqueous formaldehyde solutions in the presence
of concentrated sulfuric acid as a catalyst. The process for the
production of trioxane known in the prior art is complex and
comprises an extraction step which necessitates tedious solvent
recovery steps. Furthermore, the process known in the prior art is
time and energy consuming and leads to a low degree of conversion
of the formaldehyde source into the desired cyclic acetals (final
conversion of less than 10% in the liquid reaction mixture).
Furthermore, the amount of side products formed by the process is
high.
Technically, the process for the production of trioxane in a liquid
system is generally the conversion of an aqueous formaldehyde
solution in the presence of sulfuric acid or other homogeneous or
heterogeneous catalysts. However, said technical process has
various draw backs.
Under the reaction conditions several side reactions do occur such
as the disproportionation of the formaldehyde to formic acid and
methanol (Cannizzaro reaction). The formed acid and methanol may
further react to methyl formate. Further, the work up procedure and
the separation of the cyclic acetals, in particular the trioxane,
is very time and energy consuming, complex and cost intensive. A
typical process for the production of trioxane starts with an
aqueous formaldehyde solution which is concentrated by distillation
in a first step in order to remove the volume of water or, in other
words, reduce the amount of water and thereby reduce the
concentration of water. Subsequently, the concentrated formaldehyde
solution is fed into a reactor and converted into trioxane in the
presence of a catalyst. The trioxane is separated from the reaction
mixture by distillation. However, since the trioxane forms an
azeotrope with the water contained in the aqueous medium a
subsequent extraction step and a further distillation step to
remove the extracting solvent is necessary. A characteristic of
this process is the high energy consumption for evaporating water
which is introduced into the process by the feed stock streams.
There are various proposals for preparing trioxane from
formaldehyde by gas-phase trimerization. U.S. Pat. No. 5,508,448
discloses a process for the preparation of trioxane from
formaldehyde in the gas phase which process comprises contacting
the formaldehyde with a solid catalyst comprising vanadyl
hydrogenphosphate hemihydrates in the gas phase.
However, the gas phase processes generally lead to a low conversion
of the formaldehyde source into the cyclic acetal. Furthermore, gas
reactions require expensive reaction equipment such as pressure
resistant vessels and, above all, the reactions are difficult to
control.
Thus, the methods for the production of trioxane known in the prior
art require several costly separation steps and are less
efficient.
There is a demand to convert formaldehyde sources which are present
in an aqueous reaction mixture into cyclic acetals in an efficient
manner.
It was an object of the present invention to provide a process for
the production of cyclic acetals which is more efficient, leads to
a higher final conversion and produces cyclic acetals with less
side products even in the presence of protic compounds. Further, it
was an object of the invention to provide a process for the
production of cyclic acetals in a liquid system wherein the energy
consumption is reduced and the separation of the cyclic acetals is
less complex.
It has been surprisingly found that the problems associated with
the methods disclosed in the prior art can be overcome by forming
trioxane and other cyclic acetals derived from formaldehyde in the
presence of an aprotic compound. It has been found that even in the
presence of protic compounds excellent results in terms of reduced
energy consumption and a lower complexity of the separation
procedure can be obtained. Further, it has been found that the
conversion from a formaldehyde source to cyclic acetals such as
trioxane can be significantly increased.
Accordingly, in a first embodiment the present invention is
directed to a process for producing cyclic acetal comprising i)
preparing a liquid reaction mixture comprising a) a formaldehyde
source, b) an aprotic compound and c) a catalyst; d) wherein the
total amount of protic compounds is less than about 40 wt.-%, based
on the total weight of the reaction mixture; and ii) converting the
formaldehyde source into cyclic acetals.
A further embodiment of the present invention is a process for
producing a cyclic acetal comprising reacting a formaldehyde source
in the presence of a catalyst wherein the reaction is carried out
in a liquid medium comprising an aprotic compound and one or more
protic compound(s), wherein the total amount of protic compounds is
less than about 40 wt.-%, based on the total weight of the reaction
mixture. Protic compounds are compounds that can donate a proton
under reaction conditions. Typical protic compounds are water,
methanol and Bronsted acids. It should be understood that in the
context of the present invention the oligomethylene glycols present
in the reaction mixture are not counted as protic compounds.
An alternative embodiment of the present invention is a process for
producing cyclic acetal from a formaldehyde source in the presence
of a catalyst and a liquid medium comprising an aprotic compound
and one or more protic compound(s), wherein the total amount of
protic compounds is less than about 40 wt.-%, based on the total
weight of the reaction mixture.
A further embodiment of the present invention is a liquid reaction
mixture comprising a) a formaldehyde source, b) an aprotic compound
and c) a catalyst wherein the total amount of protic compounds is
less than about 40 wt.-%, based on the total weight of the reaction
mixture.
According to a preferred embodiment of the invention the liquid
medium is the aprotic compound.
Preferred embodiments of the present invention are a process for
producing cyclic acetal comprising reacting a formaldehyde source
in the presence of a catalyst wherein the reaction is carried out
in a liquid aprotic compound or, phrased differently, a process for
producing cyclic acetal from a formaldehyde source in the presence
of a catalyst and a liquid aprotic compound.
A further alternative embodiment is a process for producing cyclic
acetal comprising i) preparing a liquid mixture (A) comprising a) a
formaldehyde source and b) an aprotic compound, wherein the total
amount of protic compounds is less than about 40 wt.-%, based on
the total weight of the liquid mixture (A); ii) adding a catalyst
to the liquid mixture (A); and iii) converting the formaldehyde
source into cyclic acetals.
A further embodiment is a process for producing cyclic acetal
comprising i) preparing a liquid mixture (A) comprising a) a
formaldehyde source and b) an aprotic compound, wherein the total
amount of protic compounds is less than about 40 wt.-%, based on
the total weight of the liquid mixture (A); ii) contacting the
liquid mixture (A) with a catalyst; and iii) converting the
formaldehyde source to cyclic acetal.
A further alternative embodiment of the present invention is a
process for producing cyclic acetal comprising contacting a
reaction mixture comprising a source of formaldehyde and a liquid
medium comprising less than 40 wt. % of protic compound(s) and
further comprising a condensed compound which does not accept a
proton from nor donate electrons to said catalyst, with a
catalyst.
A further embodiment of the present invention is a process for
producing cyclic acetal comprising i) preparing a liquid reaction
mixture comprising a) a formaldehyde source which is at least
partly dissolved, preferably completely dissolved in a protic
compound, b) an aprotic compound and c) a catalyst; and ii)
converting the formaldehyde source into cyclic acetals.
A process for producing cyclic acetal comprising i) preparing a
liquid reaction mixture comprising a) a formaldehyde source, b) an
aprotic compound, c) a catalyst and d) up to 40 wt.-% of a protic
compound; preferably the protic compound is non-catalytic, more
preferably the protic compound is selected from the group
consisting of water, methanol, formic acid and mixtures thereof;
and ii) converting the formaldehyde source into cyclic acetals.
Preferably, the liquid reaction mixture comprises 5 to 38 wt.-%,
more preferably 10 to 35 wt.-% and especially 15 to 30 wt.-% of a
protic compound. Preferably the protic compound is selected from
the group consisting of water, methanol and formic acid and
mixtures thereof.
The protic compound is usually a chain transfer agent. That is to
say, that the protic compound is able to react with monomeric
formaldehyde and thereby reduces the degree of oligomerization of
the methylene glycols, which essentially comprise the organic
species in a concentrated aqueous formaldehyde solution. By
reacting with formaldehyde the protic compound forms endgroups of
the oligomethylene glycols. Typical protic compounds are:
Water, leading to OH-endgroups
Methanol, leading to OH-- and methoxy-endgroups
Formic acid, leading to OH-- and formate endgroups
Phosphoric acid, leading to OH-- and phosphate endgroups
It has been found that aqueous formaldehyde solutions can be
converted with an increased degree of conversion to cyclic acetals.
Moreover, it has been found that it is possible to run the reactor
at lower temperatures compared to the process known in the prior
art where only aqueous formaldehyde solutions are converted in the
presence of sulfuric acid. Specifically it has been found that the
presence of the aprotic compound leads to distillates during the
work-up of the cyclic acetals, in particular the trioxane, which
contains more trioxane and less formaldehyde compared to the
process without the aprotic compound. Thus, the process is much
more cost effective.
The term "liquid" used in the present invention in conjunction with
the aprotic compound, the medium, the mixture (A) and the reaction
mixture refers to the reaction conditions. Under the reaction
conditions the liquid system in which the reaction of the
formaldehyde source to the cyclic acetal is carried out is
liquid.
An advantage of the present invention is that the conversion of the
formaldehyde source is carried out in a liquid system, e.g., a
liquid reaction mixture or a liquid medium or a liquid mixture (A).
However, even though it is advantageous the components of the
reaction mixture or the liquid mixture (A) must not necessarily be
completely dissolved. Thus the reaction mixture or the liquid
mixture (A) may also comprise solids or molten components which are
not dissolved.
The formaldehyde source reacts (converts) to cyclic acetals in the
presence of a catalyst. Usually, cationic catalysts, such as
Bronsted acids or Lewis acids, accelerate the conversion of the
formaldehyde source to the desired cyclic acetals.
The catalyst is a catalyst for the conversion (reaction) of a
formaldehyde source into cyclic acetals, in particular into
trioxane and/or tetroxane.
The methods of the present invention refer to the production of
cyclic acetals. Cyclic acetals within the meaning of the present
invention relate to cyclic acetals derived from formaldehyde.
Typical representatives are showing the following formula:
##STR00001## wherein a is an integer ranging from 1 to 3.
Preferably, the cyclic acetals produced by the process of the
present invention are trioxane (a=1) and/or tetroxane (a=2).
Trioxane and Tetroxane usually form the major part (at least 80
wt.-%, preferably at least 90 wt.-%) of the cyclic acetals formed
by the process of the present invention.
The weight ratio of trioxane to tetroxane varies with the catalyst
used. Typically, the weight ratio of trioxane to tetroxane ranges
from about 3:1 to about 40:1, preferably about 4:1 to about
20:1.
The process and the reaction mixture and the liquid mixture (A) of
the present invention may comprise a condensed compound which does
not accept a proton or nor donate electrons to the catalyst. In
other words the condensed compound does not deactivate the
catalyst.
Preferably, the process and the reaction mixture and the liquid
mixture (A) of the present invention comprises an aprotic compound.
Contrary to protic compounds such as acids, alcohols and water
having protons which can be removed relatively easy from the hetero
atoms, aprotic compounds preferably have only hydrogen atoms which
are linked to carbon atoms (F. A. Carey, R. J. Lundberg, Organische
Chemie, Verlag VCH, 1995, page 224). Generally, aprotic compounds
do not contain hydrogen atoms which can dissociate i.e., form
protons under the reaction conditions.
Advantageously, the aprotic compound does not essentially
deactivate the catalyst. Generally, the catalysts used for the
formation of cyclic acetals from a formaldehyde source are cationic
catalysts, such as Bronsted acids or Lewis acids. Preferably, under
the reaction conditions the aprotic compound does essentially not
deactivate the catalyst used in the process of the present
invention. Aprotic solvents such as dimethylformamide (DMF),
dimethylacetamide (DMAC) or N-methylpyrrolidone (NMP) are too basic
and therefore may deactivate the catalyst and, as a consequence,
said solvents are less suitable. According to a preferred
embodiment of the present invention the liquid reaction mixture is
essentially free of amides, preferably essentially free of acyclic
or cyclic amides. Essentially free means that the amides may be
present in an amount of less than about 5 wt.-%, preferably less
than about 2 wt.-%, more preferably less than 0.5 wt.-%, especially
less than about 0.01 wt.-% and, in particular, less than 0.001
wt.-% or about 0 wt.-%, wherein the weight is based on the total
weight of the liquid reaction mixture. Within the meaning of the
present invention the aprotic compound does not deactivate the
catalyst if under the reaction conditions less than about 95%,
preferably less than about 50%, more preferably less than about
10%, of the Bronsted acid catalyst used protonates the aprotic
compound. In case a Lewis acid catalyst is used the aprotic
compound does not deactivate the catalyst if under the reaction
conditions less than about 90 wt-%, preferably less than about 50
wt.-%, more preferably less than about 10 wt-% of the Lewis acid
catalyst forms a complex with the aprotic compound.
The degree of protonation and complex formation can be determined
by NMR spectroscopy such as or .sup.1H or .sup.13C-NMR. The degree
of protonation and complex formation is determined at 25.degree.
C., preferably in d.sub.6-DMSO.
The deactivation of the catalyst can also be determined in the
following manner: 10 g of commercially available paraformaldehyde
(95 wt %) is dissolved in 100 g of sulfolane at a temperature
sufficient to dissolve the paraformaldehyde in such a way that no
gaseous formaldehyde can escape. The clear solution is kept at
90.degree. C. and 0.1 wt % of triflic acid is added. The rate of
the formation of trioxane is measured (by measuring the
concentration of trioxane as a function of time).
The same experiment is repeated, except that 10 g of the sulfolane
are replaced by 10 g of the aprotic compound to be tested. If the
rate of trioxane formation is still greater than about 1%,
preferably greater than about 5%, more preferably greater than
about 10%, of the rate of the initial experiment then it is
concluded that the aprotic compound in question does not deactivate
the catalyst (even though it may reduce its activity).
The aprotic compound should not be too basic in order to avoid
deactivation of the catalysts. Likewise, the aprotic compound
preferably does not chemically react with the formaldehyde source
under the reaction conditions.
Preferably, under the reaction conditions the aprotic compound
should not react chemically with the formaldehyde source or the
cyclic acetal obtained by the process of the invention. Compounds
like water and alcohols are not suitable as they react with
formaldehyde. Within the meaning of the present invention an
aprotic compound does not chemically react with the formaldehyde
source when it meets the following test criteria: 5 g of
commercially available paraformaldehyde (95 wt.-%) is added to 100
g of the aprotic compound containing 0.1 wt.-%
trifluoromethanesulfonic acid and heated at 120.degree. C. for 1
hour with stirring in a closed vessel so that no gaseous
formaldehyde can escape. If less than about 1 wt.-%, preferably
less than about 0.5 wt.-%, more preferably less than about 0.1
wt.-% and most preferably less than about 0.01 wt.-% of the aprotic
compound has chemically reacted, then the aprotic compound is
considered not to have reacted with the formaldehyde source.
Further, under the acidic reaction conditions the aprotic compound
should be essentially stable. Therefore, aliphatic ethers or
acetals are less suitable as aprotic compounds. The aprotic
compound is considered stable under acidic conditions within the
meaning of the present invention if the aprotic compound meets the
following test conditions: 100 g of the aprotic compound to be
tested containing 0.5% by weight (wt.-%) trifluoromethanesulfonic
acid is heated at 120.degree. C. for 1 hour. If less than about 0.5
wt.-%, preferably less than about 0.05 wt.-%, more preferably less
than about 0.01 wt.-% and most preferably less than about 0.001
wt.-% of the aprotic compound has chemically reacted, then the
aprotic compound is considered to be stable under acidic
conditions.
According to a preferred embodiment of the present invention the
aprotic compound is liquid under the reaction conditions.
Therefore, the aprotic compound may have a melting point of about
180.degree. C. or less, preferably about 150.degree. C. or less,
more preferably about 120.degree. C. or less, especially about
60.degree. C. or less.
For practical reasons it is advantageous to use an aprotic compound
which has a melting point in the order of preference (the lower the
melting point the more preferred) of below about 50.degree. C.,
below about 40.degree. C. and below about 30.degree. C. and below
about 20.degree. C. Especially, aprotic compounds which are liquid
at about 25 or about 30.degree. C. are suitable since they can
easily transported by pumps within the production plant.
Further, the aprotic compound may have a boiling point of about
120.degree. C. or higher, preferably about 140.degree. C. or
higher, more preferably about 160.degree. C. or higher, especially
about 180.degree. C. or higher, determined at 1 bar. The higher the
boiling point the better the cyclic acetals, especially trioxane
and/or tetroxane formed by the process of the present invention can
be separated by distillation. Therefore, according to an especially
preferred embodiment of the present invention the boiling point of
the aprotic compound is at least about 20.degree. C. higher than
the boiling point of the cyclic acetal formed, in particular at
least about 20.degree. C. higher than the boiling point of trioxane
and/or tetroxane.
Additionally, aprotic compounds are preferred which do not form an
azeotrope with the cyclic acetal, especially do not form an
azeotrope with trioxane.
In a preferred embodiment of the present invention the reaction
mixture comprises the aprotic compound in an amount of at least 20
wt.-%, preferably from 20 to 80 wt.-%, more preferably from 25 to
70 wt.-%, more preferably from 30 to 60 wt.-%, especially from 35
to 55 wt.-% wherein the amount is based on the total weight of the
reaction mixture. The liquid medium or the reaction mixture or the
liquid mixture (A) may comprise one or more aprotic
compound(s).
It has been found that liquid aprotic compounds which at least
partly dissolve the formaldehyde source lead to excellent results
in terms of conversion of the formaldehyde source into the desired
cyclic acetals.
Therefore, aprotic compounds are preferred which at least partly
dissolve the formaldehyde source under the reaction conditions.
Preferred are aprotic compounds which dissolve paraformaldehyde (98
wt.-% formaldehyde, 2 wt.-% water) [can also be expressed as
Pn=moles of formaldehyde/moles of water=(98/30)/(2/18)=approx. 29]
at the reaction temperature in an amount of at least about 0.1
wt.-%, wherein the weight is based on the total weight of the
solution.
Further, preferably the aprotic compound dissolves paraformaldehyde
(98 wt.-% formaldehyde, 2 wt.-% water; Pn=approx. 29) at
120.degree. C. in an amount of at least about 1 wt.-%, preferably
at least about 5 wt.-% and more preferably at least about 10 wt.-%,
wherein the weight is based on the total weight of the
solution.
The aprotic compound used in the process of the invention or the
reaction mixture or the liquid mixture (A) of the present invention
is preferably a polar aprotic compound. Polar aprotic solvents are
much more suitable to dissolve the formaldehyde source. Unpolar
aprotic compounds such as unsubstituted hydrocarbons (e.g. cyclic
hydrocarbons such as cyclohexane, or alicyclic hydrocarbons such as
hexane, octane, decane, etc.) or unsubstituted unsaturated
hydrocarbons or unsubstituted aromatic compounds are less suitable.
Therefore, according to a preferred embodiment the aprotic compound
is not an unsubstituted hydrocarbon or unsubstituted unsaturated
hydrocarbon or unsubstituted aromatic compound. Further, preferably
the reaction mixture comprises unsubstituted hydrocarbons and/or
unsubstituted unsaturated hydrocarbons and/or unsubstituted
aromatic compounds in an amount of less than about 50 wt.-%, more
preferably less than about 25 wt.-%, further preferably less than
about 10 wt.-%, especially less than about 5 wt.-%, e.g. less than
about 1 wt.-% or about 0 wt.-%.
Polar aprotic compounds are especially preferred. According to a
preferred embodiment of the invention the aprotic compound has a
relative static permittivity of more than about 15, preferably more
than about 20, more preferably of more than about 25, especially of
more than about 30, determined at 25.degree. C.
The relative static permittivity, .di-elect cons..sub.r, can be
measured for static electric fields as follows: first the
capacitance of a test capacitor C.sub.0, is measured with vacuum
between its plates. Then, using the same capacitor and distance
between its plates the capacitance C.sub.x with an aprotic compound
between the plates is measured. The relative dielectric constant
can be then calculated as
##EQU00001##
Preferred are aprotic compounds which dissolve the formaldehyde
source.
According to a preferred embodiment the formaldehyde source is at
least partially, preferably at least about 80 wt.-%, more
preferably at least about 95 wt.-%, especially completely, in
solution in the reaction mixture or liquid mixture (A).
Therefore the process of the invention is preferably carried out in
manner wherein the formaldehyde source is completely dissolved in
the liquid medium or reaction mixture or liquid mixture (A).
Therefore, according to a preferred embodiment the formaldehyde
source and the aprotic compound form a homogenous phase under the
reaction conditions.
Suitable aprotic compounds are selected from the group consisting
of organic sulfoxides, organic sulfones, organic sulfonate ester,
nitrile group containing organic compounds, halogenated aromatic
compounds, and mixtures thereof.
According to a preferred embodiment the aprotic compound is
selected from sulfur containing organic compounds.
Further, the aprotic compound is preferably selected from the group
consisting of cyclic or alicyclic organic sulfoxides, alicyclic or
cyclic sulfones, organic mono- or di-nitrile compounds, and
mixtures thereof.
Excellent results can be achieved by aprotic compounds as
represented by the following formula (I):
##STR00002## wherein n is an integer ranging from 1 to 6,
preferably 2 or 3, and wherein the ring carbon atoms may optionally
be substituted by one or more substituents, preferably selected
from C.sub.1-C.sub.8-alkyl which may be branched or unbranched.
According to the most preferred embodiment the aprotic compound is
sulfolane (tetrahydrothiophene-1,1-dioxide).
Sulfolane is an excellent solvent for the formaldehyde source, it
is stable under acidic conditions, it does not deactivate the
catalysts and it does not form an azeotrope with trioxane.
Unless indicated otherwise the expression "reaction mixture" refers
to the mixture which is used for the reaction of the formaldehyde
source to the cyclic acetals. The concentrations and amounts of the
individual components of the reaction mixture refer to the
concentrations and amounts at the beginning of the reaction. In
other words the reaction mixture is defined by the amounts of its
starting materials, i.e. the amounts of initial components.
Likewise the amounts defined for the "liquid mixture (A)" refer to
the amounts of the components at the beginning of the reaction,
i.e. prior to the reaction.
The formaldehyde source reacts to the cyclic acetals and, as a
consequence, the concentration of the formaldehyde source decreases
while the concentration of the cyclic acetals increases.
At the beginning of the reaction a typical reaction mixture of the
invention comprises a) a formaldehyde source, b) a catalyst and c)
sulfolane.
Further, an especially preferred embodiment of the present
invention is a process for producing cyclic acetal comprising
reacting a formaldehyde source in the presence of a catalyst
wherein the reaction is carried out in sulfolane or a process for
producing cyclic acetal from a formaldehyde source in the presence
of a catalyst and sulfolane.
A further preferred aprotic compound is represented by formula
(II):
##STR00003## wherein R.sup.1 and R.sup.2 are independently selected
from C.sub.1-C.sub.8-alkyl which may be branched or unbranched,
preferably wherein R.sup.1 and R.sup.2 independently represent
methyl or ethyl. Especially preferred is dimethyl sulfone.
According to a further preferred embodiment the aprotic compound is
represented by formula (III):
##STR00004## wherein n is an integer ranging from 1 to 6,
preferably 2 or 3, and wherein the ring carbon atoms may optionally
be substituted by one or more substituents, preferably selected
from C.sub.1-C.sub.8-alkyl which may be branched or unbranched.
Suitable aprotic compounds are also represented by formula
(IV):
##STR00005## wherein R.sup.3 and R.sup.4 are independently selected
from C.sub.1-C.sub.8-alkyl which may be branched or unbranched,
preferably wherein R.sup.1 and R.sup.2 independently represent
methyl or ethyl.
Especially preferred is dimethyl sulfoxide.
Suitable aprotic compounds may be selected from aliphatic
dinitriles, preferably adiponitrile.
The reaction mixture typically comprises the aprotic compound in an
amount ranging from about 20 to about 99.85 wt.-%, preferably from
about 30 to about 99.5 wt.-% or about 30 to about 98 wt.-%, more
preferably from about 40 to about 99 wt.-%, further preferably from
about 60 to about 98 wt.-%, especially from about 80 to about 97
wt.-%, based on the total weight of the reaction mixture
Further, the reaction mixture specifically comprises the aprotic
compound in an amount ranging from 25 to 90 wt.-%, further ranging
from 25 to 75 wt.-% and in particular from 30 to 65 wt.-%, based on
the total weight of the reaction mixture.
The process of the invention is carried out in the presence of a
catalyst for the conversion of the formaldehyde source into cyclic
acetals. Suitable catalysts are any components which accelerate the
conversion of the formaldehyde source to the cyclic acetals.
The catalyst is a catalyst for the conversion (reaction) of a
formaldehyde source into cyclic acetals, preferably into trioxane
and/or tetroxane.
Usually, cationic catalysts can be used for the process of the
invention. The formation of cyclic acetals can be heterogeneously
or homogenously catalyzed. In case the catalysis is heterogeneous
the liquid mixture comprising the formaldehyde source and the
aprotic compound is contacted with the solid catalyst or an
immiscible liquid catalyst. A typical liquid immiscible catalyst is
a liquid acidic ion exchange resin. Solid catalyst means that the
catalyst is at least partly, preferably completely in solid form
under the reaction conditions. Typical solid catalysts which may be
used for the process of the present invention are acid ion-exchange
material, Lewis acids and/or Bronsted acids fixed on a solid
support, wherein the support may be an inorganic material such as
SiO.sub.2 or organic material such as organic polymers.
However, preferred is a homogenous catalysis wherein the catalyst
is dissolved in the reaction mixture.
Preferred catalysts are selected from the group consisting of
Bronsted acids and Lewis acids. The catalyst is preferably selected
from the group consisting of trifluoromethanesulfonic acid,
perchloric acid, methanesulfonic acid, toluenesulfonic acid and
sulfuric acid, or derivatives thereof such as anhydrides or esters
or any other derivatives that generate the corresponding acid under
the reaction conditions. Lewis acids like boron trifluoride,
arsenic pentafluoride can also be used. Heteropolyacids, like
tungsten phosphoric acid can also serve as a catalyst. It is also
possible to use mixtures of all the individual catalysts mentioned
above.
The catalyst is typically used in an amount ranging from about
0.001 to about 15 wt %, preferably 0.01 to about 10 wt.-%. In one
embodiment, the catalyst is present in an amount from about 0.01%
to about 5% by weight, such as from about 1% to about 5% by
weight.
The formaldehyde source used in the process and reaction mixture
and liquid mixture (A) of the present invention can in principle be
any compound or mixtures of compounds which can generate
formaldehyde or which is formaldehyde.
A further preferred formaldehyde source is paraformaldehyde.
Preferably, the paraformaldehyde used has a water content of less
than about 15 wt.-% or less than 10 wt.-% or less than 5 wt.-%,
preferably less than about 2 wt.-%, more preferably less than about
1 wt.-%, especially less than about 0.5 wt.-%, wherein the weight
is based on the total weight of the sum of the formaldehyde source
and water.
A further preferred formaldehyde source is formaldehyde which may
be present in an aqueous solution. The formaldehyde content of the
aqueous formaldehyde solution is preferably ranging from about 60
to about 90 wt.-%, more preferably ranging from 65 to 85 wt.-% and
even more preferably from 65 wt-% to 70 wt-%, based on the total
weight of the aqueous formaldehyde solution.
The process of the invention can also be used to change the ratio
of cyclic acetals derived from formaldehyde. Therefore, the
formaldehyde source can also comprise cyclic acetals selected from
the group consisting of trioxane, tetroxane and cyclic oligomers
derived from formaldehyde.
Of course, any mixtures of the above-mentioned formaldehyde sources
can also be used.
Preferably, the reaction mixture comprises the formaldehyde source
in an amount ranging from about 0.1 to about 80 wt % or about 1 to
less than about 80 wt.-%, more preferably from about 5 to about 75
wt %, further preferably ranging from about 10 to about 70 wt % and
most preferred ranging from about 20 to about 70 wt %, especially
ranging from 30 to 60 wt.-%, further especially from 30 to 50
wt.-%, based on the total weight of the reaction mixture.
According to one embodiment, the weight ratio of formaldehyde
source to aprotic compound is ranging from about 1:1000 to about
4:1, preferably about 1:600 to about 3:1, more preferably about
1:400 to about 2:1, further preferably about 1:200 to about
1:1.
According to one preferred embodiment, the weight ratio of
formaldehyde source to aprotic compound is ranging from about 1:20
to about 20:1, preferably about 1:10 to about 10:1, more preferably
about 1:5 to about 5:1 and most preferably from about 1:2 to about
2:1.
It has been found that protic compounds in the reaction mixture
decrease the degree of conversion. Therefore, it is desired that
the amount of protic compounds is as low as possible. On the other
hand the process of the present invention can be conducted in the
presence of protic compounds. It has been found that aqueous
formaldehyde solutions can be converted with an increased degree of
conversion to cyclic acetals. Moreover, it has been found that it
is possible to run the reactor at lower temperatures compared to
the process known in the prior art where only aqueous formaldehyde
solutions are converted in the presence of sulfuric acid.
Specifically, it has been found that the presence of the aprotic
compound leads to distillates during the work-up of the cyclic
acetals, in particular the trioxane, which contains more trioxane
and less formaldehyde compared to the process without the aprotic
compound. Thus, the process is much more cost effective.
According to a preferred embodiment of the present invention the
amount of protic compounds, in particular the amount of water and
alcohols, such as methanol, and formic acid, is less than about 40
wt.-%, preferably the total amount of protic compounds in the
reaction mixture is ranging from 1 to 35 wt.-%, preferably 2 to 30
wt.-%, more preferably ranging from 5 to 25 wt.-% or 10 to 20 wt.-%
or 5 to 15 wt.-%, based on the total weight of the reaction
mixture.
Further, according to a preferred embodiment the protic compound
forms a homogenous phase with the formaldehyde source.
According to an especially preferred embodiment of the invention
the amount of water in the reaction mixture is less than about 30
wt.-%, preferably less than about 25 wt.-%, more preferably less
than about 10 wt.-%, further preferably less than about 5 wt.-%,
based on the total amount of the liquid reaction mixture.
Typically, the reaction mixture comprises protic compounds, which
are different from the catalyst, and selected from the group
consisting of water, aliphatic alcohols, formic acid, phosphoric
acid and sulfuric acid and mixtures thereof, preferably selected
from water, methanol and formic acid.
A preferred embodiment of the process of the present invention is a
process for producing cyclic acetal comprising i) preparing a
liquid reaction mixture comprising a) 0.1 to less than 80 wt.-% of
a formaldehyde source, b) 20 to 99.85 wt.-% of an aprotic compound
and c) 0.001 to 15 wt % of a catalyst; and ii) at least partially
converting the formaldehyde source into cyclic acetals.
An especially preferred embodiment of the present invention is a
process for producing cyclic acetal, preferably trioxane and/or
tetroxane, comprising i) preparing a liquid reaction mixture
comprising a) 20 to 70 wt.-%, preferably 30 to 60 wt.-%, more
preferably 30 to 50 wt.-% of a formaldehyde source, preferably
selected from the group consisting of paraformaldehyde, and an
aqueous formaldehyde solution and mixtures thereof b) 25 to 75
wt.-%, preferably 30 of 65 wt.-%, more preferably 30 to 50 wt.-% of
an aprotic compound, preferably selected from sulfolane, dimethyl
sulfoxide, dimethyl sulfone and especially sulfolane; c) 0.001 to
10 wt % of a catalyst, preferably selected from Bronsted and Lewis
acids; and d) 5 to 15 wt.-% of a protic compound selected from the
group consisting of water, methanol, formic acid and mixtures
thereof; wherein the total amount of protic compounds is less than
40 wt.-%, based on the total weight of the reaction mixture; and
ii) converting the formaldehyde source into cyclic acetals,
preferably trioxane and/or tetroxane.
Typically, the reaction is carried out at a temperature higher than
about 0.degree. C., preferably ranging from about 0.degree. C. to
about 150.degree. C., more preferably ranging from about 10.degree.
C. to about 120.degree. C., further preferably from about
20.degree. C. to about 100.degree. C.
In one embodiment, the reaction is carried out at a temperature of
from about 20.degree. C. to about 115.degree. C., such as from
about 60.degree. C. to about 110.degree. C.
A further advantageous of the process of the present invention is
that the cyclic acetals can easily be separated from the reaction
mixture. The cyclic acetal, especially the trioxane can be
separated from the reaction mixture by distillation. In case
sulfolane is used as the aprotic compound the formed trioxane can
be distilled off while almost all the sulfolane remains in the
reaction mixture. The process of the invention can be carried out
batch wise or as a continuous process.
In a preferred embodiment the process is carried out as a
continuous process wherein the formaldehyde source is continuously
fed to the liquid medium comprising the catalyst and wherein the
cyclic acetals, e.g. the trioxane, is continuously separated by
separation methods such as distillation.
According to a preferred embodiment the final conversion of the
formaldehyde source to the cyclic acetal can be greater than 10%,
based on initial formaldehyde source.
The final conversion refers to the conversion of the formaldehyde
source into the cyclic acetals in the liquid system. The final
conversion corresponds to the maximum conversion achieved in the
liquid system.
The final conversion of the formaldehyde source to the cyclic
acetals can be calculated by dividing the amount of cyclic acetals
(expressed in wt.-%, based on the total weight of the reaction
mixture) in the reaction mixture at the end of the reaction divided
by the amount of formaldehyde source (expressed in wt.-%, based on
the total weight of the reaction mixture) at the beginning of the
reaction at t=0.
For example the final conversion of the formaldehyde source to
trioxane can be calculated as: Final conversion=(amount of trioxane
in the reaction mixture expressed in weight-% at the end of the
reaction)/(amount of formaldehyde source in the reaction mixture
expressed in weight-% at t=0 [initial amount of formaldehyde source
in the reaction mixture])
According to a further preferred embodiment of the process of the
invention the final conversion of the formaldehyde source into the
cyclic acetals, preferably trioxane and/or tetroxane, is higher
than 12%.
The liquid reaction mixture of the present invention comprises a) a
formaldehyde source, b) an aprotic compound and c) a catalyst
wherein the total amount of protic compounds is less than 40 wt.-%,
based on the total weight of the reaction mixture.
The preferred amounts and components a) to c) are described
throughout the description of the present invention.
Especially preferred is a liquid reaction mixture comprising a) 5
to 70 wt.-%, preferably 20 to 70 wt.-%, more preferably 30 to 60
wt.-%, of a formaldehyde source, preferably selected from the group
consisting of gaseous formaldehyde, paraformaldehyde, an aqueous
formaldehyde solution, aqueous solutions containing trioxane, or
tetroxane or, cyclic oligomers derived from formaldehyde. When the
formaldehyde source is gaseous formaldehyde, the gaseous
formaldehyde may be combined with water vapor. The formaldehyde
source may also comprise mixtures of these formaldehyde sources. b)
25 to 90 wt.-%, preferably 25 to 75 wt.-%, more preferably 30 of 65
wt.-%, of an aprotic compound, preferably selected from sulfolane,
dimethyl sulfoxide, dimethyl sulfone and especially sulfolane; c)
0.001 to 10 wt % of a catalyst, preferably selected from Bronsted
and Lewis acids; and d) 5 to 30 wt.-% of water, wherein the amounts
are based on the total weight of the reaction mixture, wherein the
total amount of protic compounds is less than 40 wt.-%, based on
the total weight of the reaction mixture.
A further embodiment of the present invention is a liquid mixture
(A) comprising a) a formaldehyde source and b) an aprotic compound
wherein the total amount of protic compounds is less than 40 wt.-%,
based on the total weight of the liquid mixture (A).
The preferred components a) and b) for the liquid mixture (A) of
the invention are described throughout the description of the
present invention.
Preferably, the liquid mixture (A) comprises the formaldehyde
source in an amount ranging from about 0.1 to about 80 wt.-% or
about 1 to less than about 80 wt.-%, more preferably from about 5
to about 75 wt.-%, further preferably ranging from about 10 to
about 70 wt % and most preferred ranging from about 20 to about 70
wt.-%, especially ranging from 30 to 60 wt.-%, or 30 to 50 wt.-%,
based on the total weight of the liquid mixture (A).
The liquid mixture (A) typically comprises the aprotic compound in
an amount ranging from about 20 to about 99.85 wt.-%, preferably
from about 30 to about 99.5 wt.-% or about 30 to about 98 wt.-%,
more preferably from about 40 to about 99 wt.-%, further preferably
from about 60 to about 98 wt.-%, especially from about 80 to about
97 wt.-%, based on the total weight of the liquid mixture (A).
Further the reaction mixture specifically comprises the aprotic
compound in an amount ranging from about 25 to about 90 wt.-%,
further ranging from about 25 to about 75 wt.-% and in particular
from about 30 to about 65 wt.-% or 40 to 60 wt.-%, based on the
total weight of the liquid mixture (A).
According to an especially preferred embodiment of the invention
the amount of water in the liquid mixture (A) is less than about 38
wt.-%, preferably less than about 35 wt.-%, more preferably less
than about 25 wt.-%, further preferably less than about 20 wt.-%,
especially preferably less than about 15 wt.-%, based on the total
amount of the liquid mixture (A). Preferably, the amount of water
ranges from 5 to 15 wt.-%, based on the total amount of the liquid
mixture (A).
A further preferred embodiment is a process for producing cyclic
acetal comprising i) preparing a liquid mixture (A) comprising a) a
formaldehyde source and b) an aprotic compound; ii) contacting the
liquid mixture (A) with a catalyst; and iii) converting the
formaldehyde source into cyclic acetal.
According to this embodiment of the present invention a liquid
mixture (A) as defined above can be prepared and contacted with a
catalyst as defined above. According to a preferred embodiment the
catalyst is a solid catalyst which at least remain partly solid
under the reaction conditions. Preferably the catalyst is selected
from fixed bed catalyst, acid ion-exchange material and solid
support carrying Bronsted and/or Lewis acids.
The liquid mixture (A) is preferably comprising a) 5 to 70 wt.-%,
preferably 20 to 70 wt.-%, more preferably 30 to 60 wt.-%, of a
formaldehyde source, preferably selected from the group consisting
of gaseous formaldehyde, paraformaldehyde, an aqueous formaldehyde
solution, trioxane, tetroxane, cyclic oligomers derived from
formaldehyde and mixtures thereof, b) 25 to 90 wt.-%, preferably 25
to 75 wt.-%, more preferably 30 of 65 wt.-%, of an aprotic
compound, preferably selected from sulfolane, dimethyl sulfoxide,
dimethyl sulfone and especially sulfolane; c) optional 0.001 to 10
wt % of a catalyst, preferably selected from Bronsted and Lewis
acids; and d) less than 35 wt.-% of protic compounds, especially
water and/or methanol and/or formic acid, wherein the amounts are
based on the total weight of the liquid mixture (A).
A further embodiment of the present invention is the use of an
aprotic compound for the production of cyclic acetals, in
particular from aqueous formaldehyde.
The preferred aprotic compounds do not deactivate the catalyst, do
not form an azeotrope with trioxane and do have a boiling point of
at least 20.degree. C. higher than the boiling point of trioxane at
1 bar.
The preferred aprotic compounds are defined throughout the
description. Preferably a polar aprotic compound, more preferably
selected from the group consisting of sulfolane, dimethyl
sulfoxide, dimethyl sulfone and especially sulfolane, is used for
the production of cyclic acetals, preferably trioxane and/or
tetroxane.
A first preferred aspect of the present invention refers to: 1. A
process for producing a cyclic acetal comprising: reacting a
formaldehyde source in the presence of a catalyst to produce a
cyclic acetal, and wherein the reaction is carried out in a liquid
medium comprising a liquid aprotic compound having a boiling point
of 120.degree. C. or higher determined at 1 bar, and wherein the
amount of the liquid aprotic compound comprises at least 20 wt % of
the liquid medium. 2. A process for producing a cyclic acetal
comprising: reacting a formaldehyde source in the presence of a
catalyst to produce a cyclic acetal, and wherein the reaction is
carried out in a liquid medium comprising a liquid aprotic compound
having a boiling point of 120.degree. C. or higher determined at 1
bar, and wherein the aprotic compound does not chemically react
with the formaldehyde source during the reaction. A further
embodiment of this first aspect of the present invention is a
process for producing a cyclic acetal comprising reacting a
formaldehyde source in the presence of a catalyst wherein the
reaction is carried out in a liquid medium comprising an aprotic
compound and one or more protic compound(s), wherein the total
amount of protic compounds is less than about 40 wt.-%, based on
the total weight of the reaction mixture. Protic compounds are
compounds that can donate a proton under reaction conditions.
Typical protic compounds are water, methanol and Bronsted acids. It
should be understood that in the context of the present invention
the oligomethylene glycols present in the reaction mixture are not
counted as protic compounds. An alternative embodiment of this
first aspect of the present invention is a process for producing
cyclic acetal from a formaldehyde source in the presence of a
catalyst and a liquid medium comprising an aprotic compound and one
or more protic compound(s), wherein the total amount of protic
compounds is less than about 40 wt.-%, based on the total weight of
the reaction mixture.
A second preferred aspect of the present invention refers to: 1. A
process for producing cyclic acetal comprising i) preparing a
liquid reaction mixture comprising a) a formaldehyde source, b) an
aprotic compound and c) a catalyst; wherein the total amount of
protic compounds is less than 40 wt.-%, based on the total weight
of the reaction mixture; and ii) converting the formaldehyde source
into cyclic acetals. A further embodiment of this second aspect of
the present invention is a process for producing cyclic acetal
comprising reacting a formaldehyde source in the presence of a
catalyst wherein the reaction is carried out in a liquid medium
comprising an aprotic compound and one or more protic compound(s),
which are different from the catalyst, or non-catalytic protic
compounds, wherein the total amount of protic compounds (sum of
catalyst, if protic, and protic compound(s) different from the
catalyst) is less than about 40 wt.-%, based on the total weight of
the reaction mixture. An alternative embodiment of this second
aspect of the present invention is a process for producing cyclic
acetal from a formaldehyde source in the presence of a catalyst and
a liquid medium comprising an aprotic compound and one or more
protic compound(s), which are different from the catalyst, or
non-catalytic protic compound(s), wherein the total amount of
protic compounds (sum of catalyst, if protic, and protic
compound(s) different from the catalyst) is less than about 40
wt.-%, based on the total weight of the reaction mixture. 2. A
process according to item 1. wherein the aprotic compound is liquid
under the reaction conditions. 3. A process according to item 1. or
2. wherein the aprotic compound has a boiling point of 120.degree.
C. or higher, preferably 140.degree. C. or higher, more preferably
160.degree. C. or higher, especially 180.degree. C. or higher,
determined at 1 bar. 4. A process according to one or more of the
preceding items wherein the reaction mixture comprises the aprotic
compound in an amount of at least 20 wt.-%, preferably from 20 to
80 wt.-%, more preferably from 25 to 70 wt.-%, more preferably from
30 to 60 wt.-%, especially from 35 to 55 wt.-% wherein the amount
is based on the total weight of the reaction mixture. 5. A process
according to one or more of the preceding items wherein the aprotic
compound is selected from the group consisting of organic
sulfoxides, organic sulfones, organic sulfonate ester, nitrile
group containing organic compounds, halogenated aromatic compounds,
nitro group containing aromatic compounds and mixtures thereof,
preferably the aprotic compound is selected from sulfur containing
organic compounds. 6. A process according to one or more of the
preceding items wherein the aprotic compound is selected from the
group consisting of cyclic or alicyclic organic sulfoxides,
alicyclic or cyclic sulfones, organic mono- or di-nitrile
compounds, nitrobenzene and mixtures thereof. 7. A process
according to one or more of the preceding items wherein the aprotic
compound is represented by formula (I):
##STR00006## wherein n is an integer ranging from 1 to 6,
preferably 2 or 3, and wherein the ring carbon atoms may optionally
be substituted by one or more substituents, preferably selected
from C1-C8-alkyl which may be branched or unbranched. 8. Process
according to one or more of the preceding items wherein the aprotic
compound is sulfolane. 9. Process according to one or more of items
1 to 6 wherein the aprotic compound is represented by formula
(II):
##STR00007## wherein R.sup.1 and R.sup.2 are independently selected
from C1-C8-alkyl which may be branched or unbranched, preferably
wherein R.sup.1 and R.sup.2 independently represent methyl or
ethyl, preferably the aprotic compound is dimethyl sulfone. 10.
Process according to one or more of items 1 to 6 wherein the
aprotic compound is represented by formula (III):
##STR00008## wherein n is an integer ranging from 1 to 6,
preferably 2 or 3, and wherein the ring carbon atoms may optionally
be substituted by one or more substituents, preferably selected
from C1-C8-alkyl which may be branched or unbranched; or the
aprotic compound is represented by formula (IV):
##STR00009## wherein R.sup.3 and R.sup.4 are independently selected
from C1-C8-alkyl which may be branched or unbranched, preferably
wherein R.sup.1 and R.sup.2 independently represent methyl or
ethyl; preferably the aprotic compound is dimethyl sulfoxide. 11.
Process according to one or more of the preceding items wherein the
total amount of protic compounds in the reaction mixture is ranging
from 1 to 35 wt.-%, preferably 2 to 30 wt.-%, more preferably
ranging from 5 to 25 wt.-% or 10 to 20 wt.-% or 5 to 15 wt.-%,
based on the total weight of the reaction mixture. 12. Process
according to one or more of the preceding items wherein the
reaction mixture comprises protic compounds selected from the group
consisting of water, methanol, formic acid and mixtures thereof.
13. Process according to one or more of the preceding items wherein
the formaldehyde source and the aprotic compound form a homogenous
phase and/or the formaldehyde source and the protic compound form a
homogenous phase. 14. Process according to one or more of the
preceding items wherein the aprotic compound does not accept a
proton from nor donate electrons to the catalyst. 15. Liquid
reaction mixture comprising a) a formaldehyde source, b) an aprotic
compound and c) a catalyst; wherein the total amount of protic
compounds is less than 40 wt.-%, based on the total weight of the
reaction mixture.
EXAMPLES
Example 1
500 g of an aqueous 80 wt. % solution of formaldehyde were mixed
with 500 g of sulfolane at 80.degree. C. 40 g of concentrated
sulfuric acid were added and the clear mixture was heated to
100.degree. C. and kept there for 15 min. Then 50 ml were distilled
off at atmospheric pressure and analyzed:
The distillate contained:
32 wt % trioxane 0.05 wt % methyl formate
Comparative Example 2
To 100 g of a 60 wt.-% solution of formaldehyde in water at
100.degree. C. 5 g of sulfuric acid is added. After 15 min ca. 5 g
were distillated off at atmospheric pressure. The trioxane
concentration in the distillate was 22 wt.-%.
This shows that the process of the invention is more effective and
requires less energy to separate the cyclic acetal due to the
higher trioxane concentration in the distillate.
Example 3
9 g of commercial paraformaldehyde with a water content of ca. 4 wt
% (essay: 96 wt % from Acros Organics) were added to 91 g of
sulfolane at 145.degree. C. with stirring. As the paraformaldehyde
dissolves, the temperature decreases to 122.degree. C. The clear
solution was allowed to cool to 100.degree. C. At that temperature
0.3 ml of a 10 wt % solution of triflic acid in sulfolane was
added. After 1 min, the homogeneous solution was allowed to cool to
60.degree. C., was neutralized with triethylamine and then
analyzed. The following composition was found: Trioxane: 7.0 wt %
Tetroxane: 0.6 wt % Formaldehyde: 1 wt %
Example 4
10 g of dried Polyoxymethylene Copolymer (with a low Dioxolane
content) (TICONA trade name: Hostaform.RTM. HS 15) with melt index
of 1.5 g/10 min were dissolved in 90 g of sulfolane at 145.degree.
C. with stirring. The clear solution was added to 20 g sulfolane
(at 120.degree. C.) containing 0.4 ml of a 10 wt % solution of
triflic acid in sulfolane. After the addition was completed, the
homogeneous solution was cooled to 60.degree. C., neutralized with
triethylamine and then analyzed. The following composition was
found: Trioxane: 7.1 wt % Tetroxane: 0.75 wt % Formaldehyde: 0.4 wt
% Methylformate: <20 ppm
Example 5
Example 4 was repeated, except that perchloric acid (70 wt % in
water) was used for triflic acid:
10 g of dried Polyoxymethylene Copolymer (with a low Dioxolane
content) (TICONA trade name: Hostaform.RTM. HS 15) with melt index
of 1.5 g/10 min were dissolved in 90 g of sulfolane at 145.degree.
C. with stirring. The clear solution was added to 20 g sulfolane
(at 120.degree. C.) containing 1.2 ml of a 2 wt % solution of
perchloric acid (70 wt % in water) in sulfolane. After the addition
was completed, the homogeneous solution was cooled to 60.degree.
C., neutralized with triethylamine and then analyzed. The following
composition was found: Trioxane: 7.2 wt % Tetroxane: 0.8 wt %
Formaldehyde: 0.3 wt % Methylformate: <20 ppm
Comparative Example 6
Example 4 was repeated, except that nitrobenzene was used for
sulfolane as a solvent:
10 g of dried Polyoxymethylene Copolymer (with a low Dioxolane
content) (TICONA trade name: Hostaform.RTM. HS 15) with melt index
of 1.5 g/10 min were dissolved in 90 g of nitrobenzene at
145.degree. C. with stirring. The clear solution was added to 20 g
nitrobenzene (at 120.degree. C.) containing 0.4 ml of a 10 wt %
solution of triflic acid in sulfolane. After the addition was
completed, the homogeneous solution was cooled to 60.degree. C.,
neutralized with triethylamine and then analyzed. The following
composition was found: Trioxane: 6.2 wt % Tetroxane: 0.7 wt %
Formaldehyde: 0.7 wt % Methylformate: 0.5 wt %
The GC spectrum also showed a new peak with a retention time beyond
that of nitrobenzene, which was not further analyzed but is
believed to be a reaction product of nitrobenzene with
formaldehyde. Thus, nitrobenzene is not stable under reaction
conditions, produces side products (methylformate) and consequently
has a lower yield in trioxane.
Example 7
Example 4 was repeated, except that a mixture of Dimethylsulfone
(30 g) and Sulfolane (60 g) was used for sulfolane as a
solvent:
10 g of dried Polyoxymethylene Copolymer (with a low Dioxolane
content) (TICONA trade name: Hostaform.RTM. HS 15) with melt index
of 1.5 g/10 min were dissolved in a mixture of Dimethylsulfone (30
g) and Sulfolane (60 g) at 145.degree. C. with stirring. The clear
solution was added to 20 g sulfolane (at 120.degree. C.) containing
0.4 ml of a 10 wt % solution of triflic acid in sulfolane. After
the addition was completed, the homogeneous solution was cooled to
60.degree. C., neutralized with triethylamine and then analyzed.
The following composition was found: Trioxane: 7.1 wt % Tetroxane:
0.6 wt % Formaldehyde: 0.8 wt % Methylformate: 9.4 ppm
Example 8
Example 3 was repeated except that strongly acidic ion exchange
resin (Amberlyst 15.RTM., wet form, from DOW CHEMICAL) was used
instead of triflic acid as catalyst.
Before use the resin was conditioned to sulfolane (exchange of
water in the pores of the resin by sulfolane)
9 g of commercial paraformaldehyde with a water content of ca. 4 wt
% (essay: 96 wt % from Acros Organics) were added to 91 g of
sulfolane at 145.degree. C. with stirring. As the paraformaldehyde
dissolves the temperature decreases to 122.degree. C. The clear
solution was allowed to cool to 100.degree. C. At that temperature
10 g of Amberlyst 15.RTM. was added. After 10 min at 100.degree. C.
the reaction mixture was allowed to cool to 50.degree. C., and no
precipitate formed, indicating the conversion of the
paraformaldehyde to trioxane. The concentration of the trioxane in
the reaction mixture is estimated to be above 6 wt %.
* * * * *
References